Thermosetting resin composition for high performance laminates

Abstract

This invention concerns a thermosetting resin system that is useful in the manufacture of high performance prepreg, laminate and composite materials as well as the prepregs, laminates and composites made from the thermosetting resin composition.

1. A thermosetting resin composition comprising:
 at least one elastomer; 
 at least one polyester; and 
 at least one flame retardant, 
 
       wherein the at least one elastomer is selected from the group consisting of a styrene-butadiene-divinylbenzene terpolymer, a maleinized polybutadiene styrene copolymer, and mixtures thereof, and wherein total polyester content of the thermosetting resin composition is from about 1 wt % to about 15 wt % as a percentage of the composition solids content. 
     
     
       2. The composition of  claim 1  wherein the at least one elastomer comprises from about 20 wt % to about 60 wt %; and the at least one flame retardant comprises from about 5 wt % to about 50 wt %, each as a percentage of the composition solids content. 
     
     
       3. The composition of  claim 1  wherein the at least one polyester is an unsaturated polyester. 
     
     
       4. The composition of  claim 1  further comprising at least one catalyst. 
     
     
       5. The composition of  claim 4  wherein the at least one catalyst is a peroxide catalyst. 
     
     
       6. The composition of  claim 5  wherein the at least one catalyst is selected from dicumyl peroxide, tert-butyl peroxbenzoate, and mixtures thereof. 
     
     
       7. The composition of  claim 4  wherein the at least one catalyst comprises about 2 wt % to about 8 wt % as a percentage of the composition solids content. 
     
     
       8. The composition of  claim 1  further comprising at least one filler selected from the group consisting of PTFE fluoropolymer resin, talc, quartz, ceramics, particulate metal oxides, silica, titanium dioxide, alumina, ceria, clay, boron nitride, wollastonite, and mixtures thereof. 
     
     
       9. The composition of  claim 8  wherein the filler comprises about 5% to about 40% as a percentage of the composition solids content. 
     
     
       10. The composition of  claim 8  wherein the filler is silane treated fused silica. 
     
     
       11. The composition of  claim 1  wherein the at least one flame retardant is decabromodiphenylethane. 
     
     
       12. The composition of  claim 1  wherein the elastomer comprises from about 20 wt % to about 60 wt % as a percentage of the composition solids content. 
     
     
       13. A thermosetting resin composition comprising:
 a polybutadiene styrene divinylbenzene terpolymer; 
 an unsaturated polyester; 
 decabromodiphenylethane; 
 fused silica; and 
 dicumyl peroxide, 
 
       wherein total polyester content of the thermosetting resin composition is from about 1 wt % to about 15 wt % as a percentage of the composition solids content. 
     
     
       14. The composition of  claim 13  wherein the terpolymer comprises from about 30 wt % to about 35 wt %; the decabromodiphenylethane comprises from about 20 wt % to about 25 wt %; the fused silica comprises from about 32 wt % to about 38 wt %; and the dicumyl peroxide comprises from about 5 wt % to about 6 wt %, each as a percentage of the composition solids content. 
     
     
       15. A prepreg comprising a thermosetting resin composition and a core material, wherein the thermosetting resin composition comprises:
 at least one elastomer; 
 at least one polyester; and 
 at least one flame retardant, 
 
       wherein the at least one elastomer is selected from the group consisting of a styrene-butadiene-divinylbenzene terpolymer, a maleinized polybutadiene styrene copolymer, and mixtures thereof, and wherein total polyester content of the thermosetting resin composition is from about 1 wt % to about 15 wt % as a percentage of the composition solids content. 
     
     
       16. The prepreg of  claim 15  wherein the at least one elastomer comprises from about 20 wt % to about 60 wt %; and the at least one flame retardant comprises from about 5 wt % to about 50 wt %, each as a percentage of the composition solids content. 
     
     
       17. The prepreg of  claim 15  wherein the at least one polyester is an unsaturated polyester. 
     
     
       18. The prepreg of  claim 15  wherein the thermosetting resin composition further comprises at least one catalyst. 
     
     
       19. The prepreg of  claim 18  wherein the at least one catalyst is a peroxide catalyst. 
     
     
       20. The prepreg of  claim 19  wherein the at least one catalyst is selected from dicumyl peroxide, tert-butyl peroxbenzoate, and mixtures thereof. 
     
     
       21. The prepreg of  claim 18  wherein the at least one catalyst comprises about 2 wt % to about 8 wt % as a percentage of the composition solids content. 
     
     
       22. The prepreg of  claim 15  wherein the thermosetting resin composition further comprises at least one filler selected from the group consisting of PTFE fluoropolymer resin, talc, quartz, ceramics, particulate metal oxides, silica, titanium dioxide, alumina, ceria, clay, boron nitride, wollastonite, and mixtures thereof. 
     
     
       23. The prepreg of  claim 22  wherein the filler comprises about 5% to about 40% as a percentage of the composition solids content. 
     
     
       24. The prepreg of  claim 22  wherein the filler is silane treated fused silica. 
     
     
       25. The prepreg of  claim 15  wherein the core material comprises a woven glass web. 
     
     
       26. The prepreg of  claim 15  wherein the at least one flame retardant is decabromodiphenylethane. 
     
     
       27. A prepreg comprising a thermosetting resin composition and a core material, wherein the thermosetting resin composition comprises:
 a polybutadiene styrene divinylbenzene terpolymer; 
 an unsaturated polyester; 
 decabromodiphenylethane; 
 fused silica; and 
 dicumyl peroxide 
 
       wherein total polyester content of the thermosetting resin composition is from about 1 wt % to about 15 wt % as a percentage of the composition solids content. 
     
     
       28. The prepreg of  claim 27  wherein the core material comprises a woven glass web. 
     
     
       29. A laminate comprising one or more prepregs and one or more sheets of conducting foil, wherein the one or more prepregs comprises a thermosetting resin composition and a core material, and wherein the thermosetting resin composition comprises: at least one elastomer; at least one polyester; and at least one flame retardant, wherein the at least one elastomer is selected from the group consisting of a styrene-butadiene-divinylbenzene terpolymer, a maleinized polybutadiene styrene copolymer, and mixtures thereof, and wherein total polyester content of the thermosetting resin composition is from about 1 wt % to about 15 wt % as a percentage of the composition solids content. 
     
     
       30. The laminate of  claim 29  wherein the one or more prepregs and the one or more sheets of conducting foil are alternately stacked. 
     
     
       31. The laminate of  claim 29  wherein in the thermosetting resin composition, the at least one elastomer comprises from about 20 wt % to about 60 wt %; and the at least one flame retardant comprises from about 5 wt % to about 50 wt %, each as a percentage of the composition solids content. 
     
     
       32. The laminate of  claim 29  wherein the at least one polyester is an unsaturated polyester. 
     
     
       33. The laminate of  claim 29  wherein the thermosetting resin composition further comprises at least one catalyst. 
     
     
       34. The laminate of  claim 33  wherein the at least one catalyst is a peroxide catalyst. 
     
     
       35. The laminate of  claim 34  wherein the at least one catalyst is selected from dicumyl peroxide, tertbutyl peroxbenzoate, and mixtures thereof. 
     
     
       36. The laminate of  claim 33  wherein the at least one catalyst comprises about 2 wt % to about 8 wt % as a percentage of the composition solids content. 
     
     
       37. The laminate of  claim 29  wherein the thermosetting resin composition further comprises at least one tiller selected from the group consisting of PTFE fluoropolymer resin, talc, quartz, ceramics, particulate metal oxides, silica, titanium dioxide, alumina, ceria, clay, boron nitride, wollastonite, and mixtures thereof. 
     
     
       38. The laminate of  claim 37  wherein the filler comprises about 5% to about 40% as a percentage of the composition solids content. 
     
     
       39. The laminate of  claim 37  wherein the filler is silane treated fused silica. 
     
     
       40. The laminate of  claim 29  wherein the one or more sheets of conducting foil are copper foil. 
     
     
       41. The laminate of  claim 29  wherein the at least one flame retardant is decabromodiphenylethane. 
     
     
       42. A laminate comprising one or more prepregs and one or more sheets of conducting foil, wherein the one or more prepregs comprises a thermosetting resin composition and a core material, and wherein the thermosetting resin composition comprises: a polybutadiene styrene divinylbenzene terpolymer; an unsaturated polyester; decabromodiphenylethane; fused silica; and dicumyl peroxide, and wherein total polyester content of the thermosetting resin composition is from about 1 wt % to about 15 wt % as a percentage of the composition solids content.